(a) The ceramics manufacturing source category consists of any facility that uses nonmetallic, inorganic materials, many of which are clay-based, to produce ceramic products such as bricks and roof tiles, wall and floor tiles, table and ornamental ware (household ceramics), sanitary ware, refractory products, vitrified clay pipes, expanded clay products, inorganic bonded abrasives, and technical ceramics (e.g., aerospace, automotive, electronic, or biomedical applications). For the purposes of this subpart, ceramics manufacturing processes include facilities that annually consume at least 2,000 tons of carbonates, either as raw materials or as a constituent in clay, which is heated to a temperature sufficient to allow the calcination reaction to occur, and operate a ceramics manufacturing process unit.

(b) A ceramics manufacturing process unit is a kiln, dryer, or oven used to calcine clay or other carbonate-based materials for the production of a ceramics product.

You must report GHG emissions under this subpart if your facility contains a ceramics manufacturing process and the facility meets the requirements of either § 98.2(a)(1) or (2).

You must report:

(a) CO2 process emissions from each ceramics process unit (e.g., kiln, dryer, or oven).

(b) CO2 combustion emissions from each ceramics process unit.

(c) CH4 and N2O combustion emissions from each ceramics process unit. You must calculate and report these emissions under subpart C of this part by following the requirements of subpart C of this part.

(d) CO2, CH4, and N2O combustion emissions from each stationary fuel combustion unit other than kilns, dryers, or ovens. You must report these emissions under subpart C of this part by following the requirements of subpart C of this part.

You must calculate and report the annual process CO2 emissions from each ceramics process unit using the procedures in paragraphs (a) through (c) of this section.

(a) For each ceramics process unit that meets the conditions specified in § 98.33(b)(4)(ii) or (iii), you must calculate and report under this subpart the combined process and combustion CO2 emissions by operating and maintaining a CEMS to measure CO2 emissions according to the Tier 4 Calculation Methodology specified in § 98.33(a)(4) and all associated requirements for Tier 4 in subpart C of this part.

(b) For each ceramics process unit that is not subject to the requirements in paragraph (a) of this section, calculate and report the process and combustion CO2 emissions from the ceramics process unit separately by using the procedures specified in paragraphs (b)(1) through (6) of this section, except as specified in paragraph (c) of this section.

(1) For each carbonate-based raw material (including clay) charged to the ceramics process unit, either obtain the mass fractions of any carbonate-based minerals from the supplier of the raw material or by sampling the raw material, or use a default value of 1.0 as the mass fraction for the raw material.

(2) Determine the quantity of each carbonate-based raw material charged to the ceramics process unit.

(3) Apply the appropriate emission factor for each carbonate-based raw material charged to the ceramics process unit. Table 1 to this subpart provides emission factors based on stoichiometric ratios for carbonate-based minerals.

(4) Use equation 1 to this paragraph (b)(4) to calculate process mass emissions of CO2 for each ceramics process unit:

(5) Determine the combined annual process CO2 emissions from the ceramic process units at your facility using equation 2 to this paragraph (b)(5):

(6) Calculate and report under subpart C of this part the combustion CO2 emissions in the ceramics process unit according to the applicable requirements in subpart C of this part.

(c) A value of 1.0 can be used for the mass fraction (MFi) of carbonate-based mineral i in each carbonate-based raw material j in equation 1 to paragraph (b)(4) of this section. The use of 1.0 for the mass fraction assumes that the carbonate-based raw material comprises 100% of one carbonate-based mineral. As an alternative to the default value, you may use data provided by either the raw material supplier or a lab analysis.

(a) You must measure annual amounts of carbonate-based raw materials charged to each ceramics process unit from monthly measurements using plant instruments used for accounting purposes, such as calibrated scales or weigh hoppers. Total annual mass charged to ceramics process units at the facility must be compared to records of raw material purchases for the year.

(b) You must use the default value of 1.0 for the mass fraction of a carbonate-based mineral, or you may opt to obtain the mass fraction of any carbonate-based materials from the supplier of the raw material or by sampling the raw material. If you opt to obtain the mass fractions of any carbonate-based minerals from the supplier of the raw material or by sampling the raw material, you must measure the carbonate-based mineral mass fractions at least annually to verify the mass fraction data. You may conduct the sampling and chemical analysis using any x-ray fluorescence test, x-ray diffraction test, or other enhanced testing method published by an industry consensus standards organization (e.g., ASTM, ASME, API). If it is determined that the mass fraction of a carbonate based raw material is below the detection limit of available industry testing standards, you may use a default value of 0.005.

(c) You must use the default value of 1.0 for the mass fraction of a carbonate-based mineral, or you may opt to obtain the mass fraction of any carbonate-based materials from the supplier of the raw material or by sampling the raw material. If you obtain the mass fractions of any carbonate-based minerals from the supplier of the raw material or by sampling the raw material, you must determine the annual average mass fraction for the carbonate-based mineral in each carbonate-based raw material at least annually by calculating an arithmetic average of the data obtained from raw material suppliers or sampling and chemical analysis.

(d) You must use the default value of 1.0 for the calcination fraction of a carbonate-based mineral. Alternatively, you may opt to obtain the calcination fraction of any carbonate-based mineral by sampling. If you opt to obtain the calcination fraction of any carbonate-based minerals from sampling, you must determine on an annual basis the calcination fraction for each carbonate-based mineral consumed based on sampling and chemical analysis. You may conduct the sampling and chemical analysis using any x-ray fluorescence test, x-ray diffraction test, or other enhanced testing method published by an industry consensus standards organization (e.g., ASTM, ASME, API).

A complete record of all measured parameters used in the GHG emissions calculations in § 98.523 is required. If the monitoring and quality assurance procedures in § 98.524 cannot be followed and data is unavailable, you must use the most appropriate of the missing data procedures in paragraphs (a) and (b) of this section in the calculations. You must document and keep records of the procedures used for all such missing value estimates.

(a) If the CEMS approach is used to determine combined process and combustion CO2 emissions, the missing data procedures in § 98.35 apply.

(b) For missing data on the monthly amounts of carbonate-based raw materials charged to any ceramics process unit, use the best available estimate(s) of the parameter(s) based on all available process data or data used for accounting purposes, such as purchase records.

(c) For missing data on the mass fractions of carbonate-based minerals in the carbonate-based raw materials, assume that the mass fraction of a carbonate-based mineral is 1.0, which assumes that one carbonate-based mineral comprises 100 percent of the carbonate-based raw material.

In addition to the information required by § 98.3(c), each annual report must contain the information specified in paragraphs (a) through (c) of this section, as applicable:

(a) The total number of ceramics process units at the facility and the number of units that operated during the reporting year.

(b) If a CEMS is used to measure CO2 emissions from ceramics process units, then you must report under this subpart the relevant information required under § 98.36 for the Tier 4 Calculation Methodology and the following information specified in paragraphs (b)(1) through (3) of this section.

(1) The annual quantity of each carbonate-based raw material (including clay) charged to each ceramics process unit and for all units combined (tons).

(2) Annual quantity of each type of ceramics product manufactured by each ceramics process unit and by all units combined (tons).

(3) Annual production capacity for each ceramics process unit (tons).

(c) If a CEMS is not used to measure CO2 emissions from ceramics process units and process CO2 emissions are calculated according to the procedures specified in § 98.523(b), then you must report the following information specified in paragraphs (c)(1) through (7) of this section.

(1) Annual process emissions of CO2 (metric tons) for each ceramics process unit and for all units combined.

(2) The annual quantity of each carbonate-based raw material (including clay) charged to each ceramics process unit and for all units combined (tons).

(3) Results of all tests used to verify each carbonate-based mineral mass fraction for each carbonate-based raw material charged to a ceramics process unit, as specified in paragraphs (c)(3)(i) through (iii) of this section.

(i) Date of test.

(ii) Method(s) and any variations used in the analyses.

(iii) Mass fraction of each sample analyzed.

(4) Method used to determine the decimal mass fraction of carbonate-based mineral, unless you used the default value of 1.0 (e.g., supplier provided information, analyses of representative samples you collected, or use of a default value of 0.005 as specified by § 98.524(b)).

(5) Annual quantity of each type of ceramics product manufactured by each ceramics process unit and by all units combined (tons).

(6) Annual production capacity for each ceramics process unit (tons).

(7) If you use the missing data procedures in § 98.525(b), you must report for each applicable ceramics process unit the number of times in the reporting year that missing data procedures were followed to measure monthly quantities of carbonate-based raw materials or mass fraction of the carbonate-based minerals (months).

In addition to the records required by § 98.3(g), you must retain the records specified in paragraphs (a) through (d) of this section for each ceramics process unit, as applicable.

(a) If a CEMS is used to measure CO2 emissions according to the requirements in § 98.523(a), then you must retain under this subpart the records required under § 98.37 for the Tier 4 Calculation Methodology and the information specified in paragraphs (a)(1) and (2) of this section.

(1) Monthly ceramics production rate for each ceramics process unit (tons).

(2) Monthly amount of each carbonate-based raw material charged to each ceramics process unit (tons).

(b) If process CO2 emissions are calculated according to the procedures specified in § 98.523(b), you must retain the records in paragraphs (b)(1) through (6) of this section.

(1) Monthly ceramics production rate for each ceramics process unit (metric tons).

(2) Monthly amount of each carbonate-based raw material charged to each ceramics process unit (metric tons).

(3) Data on carbonate-based mineral mass fractions provided by the raw material supplier for all raw materials consumed annually and included in calculating process emissions in equation 1 to § 98.523(b)(4), if applicable.

(4) Results of all tests, if applicable, used to verify the carbonate-based mineral mass fraction for each carbonate-based raw material charged to a ceramics process unit, including the data specified in paragraphs (b)(4)(i) through (v) of this section.

(i) Date of test.

(ii) Method(s), and any variations of methods, used in the analyses.

(iii) Mass fraction of each sample analyzed.

(iv) Relevant calibration data for the instrument(s) used in the analyses.

(v) Name and address of laboratory that conducted the tests.

(5) Each carbonate-based mineral mass fraction for each carbonate-based raw material, if a value other than 1.0 is used to calculate process mass emissions of CO2.

(6) Number of annual operating hours of each ceramics process unit.

(c) All other documentation used to support the reported GHG emissions.

(d) The applicable verification software records as identified in this paragraph (d). You must keep a record of the file generated by the verification software specified in § 98.5(b) for the applicable data specified in paragraphs (d)(1) through (3) of this section. Retention of this file satisfies the recordkeeping requirement for the data in paragraphs (d)(1) through (3) of this section.

(1) Annual average decimal mass fraction of each carbonate-based mineral in each carbonate-based raw material for each ceramics process unit (specify the default value, if used, or the value determined according to § 98.524) (percent by weight, expressed as a decimal fraction) (equation 1 to § 98.523(b)(4)).

(2) Annual mass of each carbonate-based raw material charged to each ceramics process unit (tons) (equation 1 to § 98.523(b)(4)).

(3) Decimal fraction of calcination achieved for each carbonate-based raw material for each ceramics process unit (specify the default value, if used, or the value determined according to § 98.524) (percent by weight, expressed as a decimal fraction) (equation 1 to § 98.523(b)(4)).

All terms used of this subpart have the same meaning given in the Clean Air Act and subpart A of this part.